Juke F15 (2012 year). Service Repair Manual — part 20

BR-14

< PERIODIC MAINTENANCE >

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BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER

Inspection

INFOID:0000000006502164

FLUID LEAK

Check for brake fluid leakage from the master cylinder mounting face, reservoir tank mounting face and brake
tube connections.

BRAKE BOOSTER

BR-15

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BRAKE BOOSTER

Inspection

INFOID:0000000006502165

OPERATION

Depress the brake pedal several times at 5-second intervals with the engine stopped. Start the engine with the
brake pedal fully depressed. Check that the clearance between brake pedal and dash lower panel decreases.
NOTE:
A slight impact with a small click may be felt on the pedal when the brake pedal is fully depressed. This is a
normal phenomenon due to the brake system operation.

AIR TIGHT

1.

Run the engine at idle for 1 minute to apply vacuum to the brake booster, and stop the engine.

2.

Depress the brake pedal several times at 5-second intervals until the accumulated vacuum is released to
atmospheric pressure. Check that the clearance between brake pedal and dash lower panel gradually
increases each time the brake pedal is depressed when performing this operation.

3.

Depress the brake pedal with the engine running. Then stop the engine while holding down the brake
pedal. Check that the brake pedal stroke does not change after holding down the brake pedal for 30 sec-
onds or more.

BR-16

< PERIODIC MAINTENANCE >

[LHD]

FRONT DISC BRAKE

FRONT DISC BRAKE

BRAKE PAD

BRAKE PAD : Inspection and Adjustment

INFOID:0000000006502221

INSPECTION

Check brake pad wear thickness from an inspection hole on cylinder
body. Check using a scale if necessary.

ADJUSTMENT

Burnish contact surfaces between disc rotor and brake pads according to the following procedure after refin-
ishing or replacing brake pads, or if a soft pedal occurs at very low mileage.

CAUTION:

• Be careful of vehicle speed because the brake does not operate firmly/securely until pads and disc

rotor are securely fitted.

• Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1.

Drive vehicle on straight, flat road.

2.

Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.

3.

Drive without depressing brake for a few minutes to cool the brake.

4.

Repeat steps 1 to 3 until pad and disc rotor are securely fitted.

DISC ROTOR

DISC ROTOR : Inspection and Adjustment

INFOID:0000000006502222

INSPECTION

Appearance

Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace it if necessary.
• MR16DDT: Refer to

FAX-11, "Removal and Installation"

.

• HR16DE: Refer to

FAX-43, "Removal and Installation"

.

• K9K: Refer to

FAX-68, "Removal and Installation"

.

Runout

1.

Fix the disc rotor to the wheel hub and bearing assembly with
wheel nuts (2 points at least).

2.

Check the wheel bearing axial end play before the inspection.
• MR16DDT: Refer to

FAX-9, "Inspection"

.

• HR16DE: Refer to

FAX-41, "Inspection"

.

• K9K: Refer to

FAX-66, "Inspection"

.

3.

Inspect the runout with a dial indicator to measure at 10 mm
(0.39 in) inside the disc edge.

4.

Find the installation position that has a minimum runout by shifting the disc rotor-to-wheel hub and bearing
assembly installation position by one hole at a time if the runout exceeds the limit value.

• Refinish the disc rotor if the runout is outside the limit even after performing the above operation.

CAUTION:

Wear thickness

: Refer to

BR-71, "Front Disc Brake"

.

BRA0010D

Runout (with it attached
to the vehicle)

: Refer to

BR-71, "Front Disc

Brake"

.

SBR019B

FRONT DISC BRAKE

BR-17

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• Check in advance that the thickness of the disc rotor is wear thickness + 0.3 mm (0.012 in) or more.
• If the thickness is less than wear thickness + 0.3 mm (0.012 in), replace the disc rotor.
- MR16DDT: Refer to

FAX-11, "Removal and Installation"

.

- HR16DE: Refer to

FAX-43, "Removal and Installation"

.

- K9K: Refer to

FAX-68, "Removal and Installation"

.

Thickness

Check the thickness of the disc rotor using a micrometer. Replace
the disc rotor if the thickness is below the wear limit.
• MR16DDT: Refer to

FAX-11, "Removal and Installation"

.

• HR16DE: Refer to

FAX-43, "Removal and Installation"

.

• K9K: Refer to

FAX-68, "Removal and Installation"

.

ADJUSTMENT

Burnish contact surfaces between disc rotors and brake pads according to the following procedure after refin-
ishing or replacing disc rotor, or if a soft pedal occurs at very low mileage.

CAUTION:

• Be careful of vehicle speed because the brake does not operate firmly/securely until pad and disc

rotor are securely fitted.

• Only perform this procedure under safe road and traffic conditions. Use extreme caution.

1.

Drive vehicle on straight, flat road.

2.

Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.

3.

Drive without depressing brake for a few minutes to cool the brake.

4.

Repeat steps 1 to 3 until pad and disc rotor are securely fitted.

Wear thickness

: Refer to

BR-71, "Front Disc Brake"

.

Wear thickness

: Refer to

BR-71, "Front Disc

Brake"

.

SBR020B

BR-18

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REAR DISC BRAKE

REAR DISC BRAKE

BRAKE PAD

BRAKE PAD : Inspection and Adjustment

INFOID:0000000006502166

INSPECTION

Check brake pad wear thickness from an inspection hole on cylinder
body. Check using a scale if necessary.

ADJUSTMENT

Burnish contact surfaces between disc rotor and brake pads according to the following procedure after refin-
ishing or replacing brake pads, or if a soft pedal occurs at very low mileage.

CAUTION:

• Be careful of vehicle speed because the brake does not operate firmly/securely until pads and disc

rotor are securely fitted.

• Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1.

Drive vehicle on straight, flat road.

2.

Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.

3.

Drive without depressing brake for a few minutes to cool the brake.

4.

Repeat steps 1 to 3 until pad and disc rotor are securely fitted.

DISC ROTOR

DISC ROTOR : Inspection and Adjustment

INFOID:0000000006502167

INSPECTION

Appearance

Check surface of disc rotor for uneven wear, cracks, and serious damage. Replace it if necessary.
• 2WD: Refer to

RAX-5, "Removal and Installation"

.

• 4WD: Refer to

RAX-14, "Removal and Installation"

.

Runout

1.

Fix the disc rotor to the wheel hub and bearing assembly with
wheel nuts (2 points at least).

2.

Check the wheel bearing axial end play before the inspection.
• 2WD: Refer to

RAX-4, "Inspection"

.

• 4WD: Refer to

RAX-12, "Inspection"

.

3.

Inspect the runout with a dial indicator to measure at 10 mm
(0.39 in) inside the disc edge.

4.

Find the installation position that has a minimum runout by shift-
ing the disc rotor-to-wheel hub and bearing assembly installation position by one hole at a time if the
runout exceeds the limit value.

• Refinish the disc rotor if the runout is outside the limit even after performing the above operation.

CAUTION:

• Check in advance that the thickness of the disc rotor is wear thickness + 0.3 mm (0.012 in) or more.

Wear thickness

: Refer to

BR-71, "Rear Disc Brake"

.

BRA0010D

Runout (with it attached
to the vehicle)

: Refer to

BR-71, "Rear Disc

Brake"

.

SBR019B

REAR DISC BRAKE

BR-19

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• If the thickness is less than wear thickness + 0.3 mm (0.012 in), replace the disc rotor.
- 2WD: Refer to

RAX-5, "Removal and Installation"

.

- 4WD: Refer to

RAX-14, "Removal and Installation"

.

Thickness

Check the thickness of the disc rotor using a micrometer. Replace
the disc rotor if the thickness is below the wear limit.
• 2WD: Refer to

RAX-5, "Removal and Installation"

.

• 4WD: Refer to

RAX-14, "Removal and Installation"

.

ADJUSTMENT

Burnish contact surfaces between disc rotors and brake pads according to the following procedure after refin-
ishing or replacing disc rotor, or if a soft pedal occurs at very low mileage.

CAUTION:

• Be careful of vehicle speed because the brake does not operate firmly/securely until pad and disc

rotor are securely fitted.

• Only perform this procedure under safe road and traffic conditions. Use extreme caution.
1.

Drive vehicle on straight, flat road.

2.

Depress brake pedal with the power to stop vehicle within 3 to 5 seconds until the vehicle stops.

3.

Drive without depressing brake for a few minutes to cool the brake.

4.

Repeat steps 1 to 3 until pad and disc rotor are securely fitted.

Wear thickness

: Refer to

BR-71, "Rear Disc Brake"

.

Wear thickness

: Refer to

BR-71, "Rear Disc

Brake"

.

SBR020B

BR-20

< REMOVAL AND INSTALLATION >

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BRAKE PEDAL

REMOVAL AND INSTALLATION

BRAKE PEDAL

Exploded View

INFOID:0000000006502170

WITHOUT ESP

WITH ESP

1.

Clevis pin

2.

Brake pedal assembly

3.

Brake pedal pad

4.

Stop lamp switch

5.

Clip

6.

Snap pin

: Apply multi-purpose grease.

: N·m (kg-m, ft-lb)

JSFIA0456GB

BRAKE PEDAL

BR-21

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Removal and Installation

INFOID:0000000006502171

REMOVAL

1.

Remove instrument lower panel. Refer to

IP-13, "Removal and Installation"

.

2.

Disconnect the stop lamp switch and the brake switch/brake pedal position switch harness connectors.

3.

Rotate the stop lamp switch and the brake switch/brake pedal
position switch (1) counter clockwise to remove.

4.

Disconnect the accelerator pedal harness connector and har-
ness clip.

1.

Clevis pin

2.

Brake pedal assembly

3.

Brake pedal pad

4.

Brake switch/brake pedal position
switch

5.

Clip

6.

Stop lamp switch

7.

Snap pin

: Apply multi-purpose grease.

: N·m (kg-m, ft-lb)

JSFIA0457GB

JPFIA0815ZZ

BR-22

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE PEDAL

5.

Remove snap pin (1) and clevis pin (2) from clevis (3) of brake
booster.

6.

Remove the steering member stay (1).

7.

Remove the brake pedal assembly.

CAUTION:

Hold the brake booster and master cylinder assembly so as
not to drop out or contact them other parts.

8.

Remove accelerator pedal from brake pedal assembly. Refer to

ACC-3, "Removal and Installation"

.

9.

Perform inspection after removal. Refer to

BR-22, "Inspection

and Adjustment"

.

INSTALLATION

Note the following, and install in the reverse order of removal.
• Apply the multi-purpose grease to the clevis pin and the mating faces. (Not necessary if grease has been

already applied)
NOTE:
The clevis pin may be inserted in either direction.

• Perform adjustment after installation. Refer to

BR-22, "Inspection and Adjustment"

.

Inspection and Adjustment

INFOID:0000000006502172

INSPECTION AFTER REMOVAL

• Check for the following items and replace the brake pedal assembly if necessary.
- Check the brake pedal upper rivet (made by aluminum) (A) for

deformation.

- Check the brake pedal for bend, damage, and cracks on the

welded parts.

- Check the lapping length (D) of sub-bracket (B) and slide plate (C).

• Check clevis pin and plastic stopper (A) for damage and deforma-

tion. If any is found, replace clevis pin.

JPFIA0816ZZ

JSFIA0458ZZ

D

: 6.5 mm (0.256 in) or more

JSFIA0459ZZ

PFIA0756J

BRAKE PEDAL

BR-23

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ADJUSTMENT AFTER INSTALLATION

• Adjust each item of brake pedal after installing the brake pedal assembly to the vehicle. Refer to

BR-9,

"Inspection and Adjustment"

.

• Perform the release position learning of the accelerator pedal.
- MR16DDT: Refer to

EC-134, "Work Procedure"

.

- HR16DE: Refer to

EC-542, "Work Procedure"

.

BR-24

< REMOVAL AND INSTALLATION >

[LHD]

BRAKE PIPING

BRAKE PIPING

FRONT

FRONT : Exploded View

INFOID:0000000006502173

WITHOUT ESP

WITH ESP

1.

Brake tube

2.

ABS actuator and electric unit (con-
trol unit)

3.

Connector

4.

Connector bracket

5.

Master cylinder assembly

6.

Brake booster

7.

Lock plate

8.

Brake hose

9.

Union bolt

10. Copper washer

A.

To rear brake tube

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

JSFIA0460GB

BRAKE PIPING

BR-25

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MR16DDT, HR16DE

JSFIA0461GB

1.

Brake tube

2.

Pressure sensor connector

3.

Pressure sensor

4.

ABS actuator and electric unit (con-
trol unit)

5.

Connector

6.

Connector bracket

7.

Master cylinder assembly

8.

Brake booster

9.

Lock plate

10. Brake hose

11.

Union bolt

12. Copper washer

A.

To rear brake tube

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

BR-26

< REMOVAL AND INSTALLATION >

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BRAKE PIPING

K9K

FRONT : Hydraulic Piping

INFOID:0000000006502174

WITHOUT ESP

JSFIA0462GB

1.

Brake tube

2.

ABS actuator and electric unit (con-
trol unit)

3.

Connector

4.

Connector bracket

5.

Master cylinder assembly

6.

Brake booster

7.

Lock plate

8.

Brake hose

9.

Union bolt

10. Copper washer

A.

To rear brake tube

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

: Always replace after every disassembly.

BRAKE PIPING

BR-27

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WITH ESP

2WD

MR16DDT, HR16DE

1.

ABS actuator and electric unit (con-
trol unit)

2.

Front disc brake

3.

Master cylinder assembly

4.

Brake booster

5.

Connector

6.

Rear disc brake

A.

Brake tube

B.

Brake hose

: Flare nut

: Union bolt

JPFIA0650ZZ

JSFIA0463ZZ

1.

ABS actuator and electric unit (con-
trol unit)

2.

Front disc brake

3.

Pressure sensor

4.

Master cylinder assembly

5.

Brake booster

6.

Connector

7.

Rear disc brake

A.

Brake tube

B.

Brake hose

: Flare nut

: Union bolt

BR-28

< REMOVAL AND INSTALLATION >

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BRAKE PIPING

K9K

4WD

JPFIA0650ZZ

1.

ABS actuator and electric unit (con-
trol unit)

2.

Front disc brake

3.

Master cylinder assembly

4.

Brake booster

5.

Connector

6.

Rear disc brake

A.

Brake tube

B.

Brake hose

: Flare nut

: Union bolt

1.

ABS actuator and electric unit (con-
trol unit)

2.

Front disc brake

3.

Pressure sensor

4.

Master cylinder assembly

5.

Brake booster

6.

Connector

7.

Rear disc brake

A.

Brake tube

B.

Brake hose

: Flare nut

: Union bolt

JSFIA0464ZZ

BRAKE PIPING

BR-29

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FRONT : Removal and Installation

INFOID:0000000006502175

REMOVAL

CAUTION:

• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it

off immediately and wash with water if it gets on a painted surface. For brake component parts,
never wash them with water.

• Never depress the brake pedal while removing the brake hose or brake tube. If this is not complied

with, brake fluid may splash.

1.

Remove tires.

2.

Drain brake fluid. Refer to

BR-12, "Draining"

.

3.

Loosen the flare nut (1) with a flare nut wrench (A) and separate
the brake tube (2) from the brake hose (3).

CAUTION:

• Never scratch the flare nut and the brake tube.
• Never bend sharply, twist or strongly pull out the brake

hoses and tubes.

• Cover open end of brake tubes and hoses when discon-

necting to prevent entrance of dirt.

4.

Remove the union bolt (1) and copper washers (2), and remove
the brake hose (3) from the brake caliper assembly.

5.

Remove the lock plate (4) and remove the brake hose.

INSTALLATION

CAUTION:

• Never spill or splash brake fluid on painted surfaces. Brake fluid may seriously damage paint. Wipe it

off immediately and wash with water if it gets on a painted surface. For brake component parts,
never wash them with water.

• Never depress the brake pedal while removing the brake hose or brake tube. If this is not complied

with, brake fluid may splash.

1.

Assemble the union bolt (1) and the copper washer (2) to the
brake hose.

CAUTION:

Never reuse the copper washer.

2.

Align the brake hose pin (A) with the brake caliper assembly
projection (B), and tighten the union bolt (1) to the specified
torque.

JPFIA0847ZZ

JPFIA0819ZZ

JPFIA0820ZZ